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Wind Technology Area Derek Berry Director, Wind Technology Area IACMI
Wind Technology Area
Derek BerryDirector, Wind Technology Area
IACMI
Wind Technology Area
Derek BerryDirector, Wind Technology Area
January 14, 2016
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• Wind turbine blade and turbine component manufacturing
• Material, labor, cycle time, reliability, recycling, light weighting
• Wind industry / National Labs / Universities
• Wind industry metric: LCOE
Wind Technology Area
Wind turbine manufacturing
Integration:• Thermoplastics• RTMAutomation (Viper)
Models for:• Preforming• Infusion• RTM• Pultrusion • Cure kinetics• Performance
• Automation• Fast resin
infusion and curing
• Intermediate scale
• Low-costcarbon fiber
• Pultrusion• Nondestructive
Evaluation• Blade recyclability
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State of Colorado Support
• $7M contribution• Actively involved in
oversight• Workforce development • Economic development• Colorado industry
• Colorado Office of Economic Development and International Trade (OEDIT)
• Fully invested in composite manufacturing development
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State of Colorado - Investment• Strong emphasis on workforce
development for existing and potential Colorado wind manufacturing facilities
• Vestas Wind (hiring 400+ composite technicians this year)
• Bach Composites
• Local manufacturing innovation space for major wind OEMs in Colorado• Siemens (Boulder), Vestas (Windsor,
Brighton and Pueblo)
• Economic development – state views the Wind TA as a potential regional hub for wind companies
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Source: Wind Vision: A New Era for Wind Power in the United States, US
Department of Energy 2015
Average wind LCOE and wind technology scale-up trends
• Ability to scale wind turbinetechnology is a driving forcein reducing the average windLCOE in the United States
Drivers of Wind Capacity Growth / Challenge
• Composite materials• Composite manufacturing
process innovation• Large blade transportation
logistics• Blade reliability
Challenges of blade transport (SSP Technology)
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Thermoplastic Composites Manufacturing
• Exploration of reactive infusion thermoplastic resins for improved cycle time, durability, recyclability
• Overcome concerns with fiber-matrix adhesion, high temperature processing and characterization
• Industrial partners: Johns Manville, TPI Composites, Arkema
• Technical Areas:• Techno-economic model• Develop spar cap baseline properties• Material development• Process development• Tooling development
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Thermoplastic Project: BP1 Work
Thermoplastic Manufacturing Process Evaluation
Criteria TP-VARTM TP-RTM TP-RIM TP Pultrusion TP-PrepregDesign freedom o
Same as thermoset process today
+
As today, but better flow length
+
As today, but better flow length
--
Fixed cross section
+
Fabric design and fiber content adjustable
Lamination processEase of production o + -
Potential fiber misalignments, potential resin
degradation due to high pressure
- ++
Decoupling of polymerization and
part production
Production costs o +
Only due to infusion and polymerization
+
Only due to infusion and polymerization
+
Continuous process
++
Continuous prepreg process
Equipment and mold costs / component
o/+
potential higher molding costs
-
Higher costs for equipment and potential mold
-
Higher costs for equipment and potential mold
+
Costs reduced due to continuous
process
++
Mainly depreciation for the continuous process
Available know how and training requirements
o
Knowhow available, training required
o
Knowhow available, training required
o
Knowhow available, training required
--
Very limited know how available
+
Know how available, training required
Production Scrap o
as today
o
as today
o
as today
+
continuous process, mainly during start
up
++
continuous process, easy to recycle
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Thermoplastic Project: BP1 Work• Definition of baseline tooling
specifications
• Master plug
• Standard production tooling• Design• Laminate• Heating system• Vacuum system• Mold framework• Bonding operation equipment• Staging
• Mold qualification
• Design tolerances
• Mold maintenance
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Thermoplastic Project: BP1 Work• Constructed backbone of techno-economic
model
• Defined baseline structural properties for wind blade spar caps
• Evaluated thermoplastic matrix choices: Caprolactam-based nylon-6 Acrylic (Arkema Elium)
• Evaluated manufacturing methods: Infusion, pultrusion, pre-preg and RTM
• Detailed potential tooling challenges for thermoplastic resin processing
• Manufactured four thermoplastic panels Panel 1,2: Nylon-6 using RTM Panel 3,4: Arkema Elium using infusion
Nylon-6 Panel Fabrication at Johns Manville
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• Continued evolution of techno-economic model • Commission laboratory scale VARTM facility at CSM
• Produce panels for each chosen combination of thermoplastic resin and manufacturing method
• Use panels to produce test coupons to determine the material properties of each combination
• Design and fabricate blade component tool to be used with thermoplastic resin composites
• Integration with the Modeling & Simulation TA and the Materials & Processing TAo Process parameter modelingo In-process non-destructive evaluation (NDE)
Thermoplastic Project: BP2 Plans
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Derek Berry(303) 717-8416
Ron Schoon(303) 275-4644
IACMI Wind TA Personnel
